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Bureau of Mines Information Circular/1983 




The Florida Phosphate Industry's 
Technological and Environmental 
Problems, A Review 

By Staff, Bureau of Mines, Tuscaloosa Research Center 




UNITED STATES DEPARTMENT OF THE INTERIOR 



^"^wm 



Information Circular 8914 



The Florida Phosphate Industry's 
Technological and Environmental 
Problems, A Review 

By Staff, Bureau of Mines, Tuscaloosa Research Center 




UNITED STATES DEPARTMENT OF THE INTERIOR 
James G. Watt, Secretary 

BUREAU OF MINES 
Robert C. Norton, Director 

Research at the Tuscaloosa Research Center is carried out under a memorandum of agreement between the 
U.S. Department of the Interior and the University of Alabama. ' : 







As the Nation's principal conservation agency, the Department of the Interior 
has responsibility for most of our nationally owned public lands and natural 
resources. This includes fostering the wisest use of our land and water re- 
sources, protecting our fish and wildlife, preserving the environmental and 
cultural values of our national parks and historical places, and providing for 
the enjoyment of life through outdoor recreation. The Department assesses 
our energy and mineral resources and works to assure that their development is 
in the best interests of all our people. The Department also has a major re- 
sponsibility for American Indian reservation communities and for people who 
live in Island Territories under U.S. administration. 



This publication has been cataloged as follows: 



The Florida phosphate industry's technological and environmental 
prohleins, a review. 

(Rureau of Mines information circular ; 8914) 

Bibliography: p. 33-34. 

Supi. of Docs, no.: 1 28.27:8914. 

1. Phosphate mines ami mining— linvironmental aspects — Florida. 

I. l.nitcd States. Bureau of Mines. luscaloosa Research C^enter. 

II. Scries; Inftirmation circular (United States. Bureau of Mines) ; 
8914. 



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CONTENTS 

Page 

Abstract 1 

Major findings 2 

Introduction 3 

Significance of the Florida phosphate Industry 3 

Production 3 

Economic contribution. 4 

Employment 4 

Taxes 5 

Florida phosphate resources 5 

Regulatory factors affecting the phosphate industry 7 

Technological factors affecting the phosphate Industry 12 

Issues associated with phosphatlc clay dewaterlng 12 

Geology and distribution of phosphatlc clays 12 

Characterization of phosphatlc clays 17 

Phosphogypsum disposal 18 

Mining of wetlands 19 

Land reclamation 20 

Status of dewaterlng technology 21 

Conventional settling process 21 

Brewster Phosphates' sand-spraying process 24 

International Minerals and Chemicals Corp. process 26 

Flocculatlon 27 

Rotary screen process 28 

Gardinier, Inc. , process 29 

Estech General Chemical Corp. process 29 

Review of dewaterlng research 29 

Phosphate land reclamation 30 

Summary 32 

References 33 

Appendix. — Chronology of establishing a phosphate operation 36 

ILLUSTRATIONS 

1. Phosphate rock processing complex.... 13 

2. Typical phosphate rock mine showing walking dragline 14 

3. Slurry pit and hydraulic monitors 15 

4. Conventional flowsheet for phosphate benef Iclatlon 16 

5. Aerial view of typical settling ponds 16 

6. Map of phosphate-producing counties 17 

7. Typical cross section of the central Florida phosphate district 17 

8. Comparison of ore constituents 18 

9. Scanning electron photomicrograph of attapulglte 19 

10. Scanning electron photomicrograph of montmorillonite 19 

11. Scanning electron photomicrograph of kaollnlte 19 

12. Phosphate land reclamation in land and lakes configuration.... 20 

13. Phosphatlc clays being discharged into a typical settling area 22 

14. Conventional clay disposal process 22 

15. Recharge well system 24 

16. Sand-spraying process for clay disposal 25 

17. Sandwich construction for sand-clay disposal process 25 

18. International Minerals and Chemicals Corp. process for clay disposal 26 

19. Rotary screen process for clay disposal 28 



11 



ILLUSTRATIONS— Continued 



Page 



20. Gardinier, Inc., process for clay disposal 29 

21. Estech General Chemical Corp. process for clay disposal 30 

TABLES 

1. Production and value of phosphate rock from Florida and North Carolina and 

the United States 4 

2. Total identified resources in recoverable product 6 

3. Permits required for phosphate mining development 7 

4. Environmental permitting requirements and costs 10 

5. Permitting schedule summary 11 

6. Reclamation cost summary for all evaluated parcels 31 



THE FLORIDA PHOSPHATE INDUSTRY'S TECHNOLOGICAL AND ENVIRONMENTAL 

PROBLEMS. A REVIEW 

By Staff, Bureau of Mines, Tuscaloosa Research Center 



ABSTRACT 

The Florida phosphate industry currently produces more than 80 pet of 
the total U.S. marketable output of phosphate rock. Because phosphate 
is one of three principal nutrients used in formulating a complete fer- 
tilizer, it is imperative that an uninterrupted supply of this material 
be available to meet the agricultural requirements of the United States 
while maintaining a viable phosphate industry which is competitive in 
world markets. As a result of an evaluation made by the Bureau of 
Mines, five areas were identified that affect the overall production and 
projected growth of the phosphate industry in Florida. These areas re- 
late to the technological ability of the industry to comply with en- 
vironmental regulations and performance standards by using the best 
available technology. The most significant technical problem facing the 
industry is the management of the clay fraction rejected during the ben- 
eficiation of phosphate ores. Other areas of concern are environmental 
restrictions and regulatory requirements, issues associated with mining 
and reclamation of wetlands, reclamation of other disturbed lands, and 
consumptive water use. 

Each of these areas is reviewed, with major emphasis placed on the 
current state-of-the-art processes for treatment and management of phos- 
phatic clays. 



MAJOR FINDINGS 



In reviewing the Florida phosphate in- 
dustry, five problem areas, which have a 
direct bearing on maintaining a viable 
critical mineral industry, were identi- 
fied as significant. These include (1) 
management of phosphatic clays, (2) regu- 
latory and environmental constraints, 
(3) mining and reclamation of wetland 
phosphate reserves, (4) reclamation of 
other disturbed lands, and (5) consump- 
tive water usage. Resolution of the 
major concern, an effective reduction in 
the total volume of stored phosphatic 
clays, would greatly reduce the magnitude 
of the other problem areas. The develop- 
ment of technology to rapidly dewater 
waste clays would permit earlier reclama- 
tion of clay settling areas, thus ad- 
dressing present objectives of the State 
of Florida to limit aboveground storage 
of phosphatic clays. Indications are, 
however, that the ultimate physical char- 
acters of clay disposal areas reclaimed 
by either the conventional settling meth- 
od or presently developing technology 
will be comparable. Even if original 
contour approximation can be achieved by 
any of the developing reclamation proce- 
dures, low-profile dams will probably 
be required until final compaction 
occurs. 

Many years and millions of dollars in 
research efforts by industry, State and 
Federal Governments, and universities 
have indeed advanced the state-of-the-art 
technology for phosphatic clay disposal. 
Nevertheless, it is evident, as a result 
of this study and review, that initial 
settling ponds or impoundment for new 
mines will continue to be necessary to 
provide — 

• Initial settling areas for clay 
solids. 

• Reservoirs for recirculating process 
water. 

• Catch-basins for area rainfall and 
control of surface runoff. 

• A potential future source of 
phosphate. 



Research has confirmed that phosphatic 
clays, from mine to mine, are extremely 
variable in chemical and mineralogical 
composition and that the settling charac- 
teristics of these clays are related to 
the mineralogy and quantity of clay pres- 
ent in the matrix. Consequently, no sin- 
gle "universal" solution to phosphatic 
clay disposal now exists for the Florida 
phosphate districts. 

Progress has been made in translating 
laboratory tests to practical field dem- 
onstrations. However, in selecting one 
or more of these methods of clay manage- 
ment, an explicit knowledge of such vari- 
ables as the operating parameters of the 
mine and processing plant, the "total" 
settling and consolidation characteris- 
tics of the clays fraction, and the total 
quantities of sand and clay in the matrix 
material is required. 

The development of mathematical models 
supported by centrifuge testing to pre- 
dict clay settling and consolidation 
parameters should prove useful in evalu- 
ating and optimizing phosphatic clay man- 
agement systems. 

The generation of phosphogypsum, a by- 
product in phosphoric acid manufacture, 
apparently presents an aesthetic problem 
rather than an environmental problem. 
Recent studies show that phosphogypsum is 
neither toxic nor corrosive, and that 
little or no leaching occurs. Seepage 
from the gypsum pond slurry is dissipated 
very rapidly and has little or no effect 
on surficial waters or deep aquifers. 

The mining of wetlands presents a spe- 
cial problem since wetlands represent 
unique ecosystems. On the other hand, if 
wetlands in the phosphate mining areas of 
Florida cannot be mined, about 500 mil- 
lion metric tons of phosphate contained 
on identified industry-owned properties 
may be lost. This amounts to 17 pet of 
Florida's reserve base. A timely major 
effort on wetlands reclamation research 
should be undertaken to determine if 
these ecosystems can be restored after 
mining. 



Reclamation of those lands not required 
for phosphatic clay storage can be read- 
ily accomplished. However, the predomi- 
nant land form will be a land and lakes 



configuration, since sufficient materials 
are not available to recreate a solid 
land form. 



INTRODUCTION 



Florida has led the Nation for nearly 
90 years in the production of phosphate 
rock (_3)1 and currently supplies more 
than 80 pet of domestic production and 34 
pet of the world output. The remaining 
domestic production comes from Alabama, 
Idaho, Montana, North Carolina, Utah, and 
Tennessee. 

Supply-demand forecasts for phosphate 
rock indicate supplies are presently ade- 
quate; however, future demand may exceed 
supply ( 29 , 34 ). Phosphate fertilizers 
are a nonsubstitutible commodity in agri- 
culture. The agricultural industry con- 
sumed over 87 pet of the national demand 
in 1980. 

Production of phosphate rock is vital 
to the Nation's agricultural production. 
Consequently, it is essential that the 
environmental problems associated with 
phosphate rock production be solved. 
While there is, as yet, no technology 
that is universally applicable to those 
problems, research is continuing, and the 
progress to date is encouraging. 

Meanwhile, the State of Florida has 
identified several facets associated with 
phosphate mining as being of concern to 
the State and has promulgated regulations 
in the areas of air and water quality, 
dam construction, and land reclamation. 



Florida, a major mining State, ranking 
first nationally in 1980 in the value of 
nonmetallic minerals produced, is unique 
in having no State mining law. However, 
county governments in the phosphate min- 
ing areas have enacted mining laws , as 
well as environmental and reclamation 
regulations which in many cases are more 
stringent than those promulgated by the 
State, and in some cases are beyond the 
technical ability of the phosphate indus- 
try to meet within the timeframe pro- 
posed. The problem of most concern is 
that of phosphate clay management. The 
solution to accelerated phosphatic clay 
dewatering beyond conventional settling 
techniques will require a technological 
breakthrough. The search for an acceler- 
ated dewatering solution currently is a 
major focus of industry and Federal re- 
search efforts. 

This study provides an overview and 
evaluation of the possible impact of reg- 
ulations on the phosphate mining indus- 
try, including a review of existing or 
proposed regulations, the magnitude of 
the problem as it affects Florida's phos- 
phate mining industry, the state-of-the- 
art and developing dewatering technology, 
and the efforts that are being made by 
government and industry to develop ac- 
ceptable technology for abating or mini- 
mizing phosphatic clay storage problems. 



SIGNIFICANCE OF THE FLORIDA PHOSPHATE INDUSTRY 



PRODUCTION 

The Florida mining industry leads the 
nation in the production of phosphates. 
In 1981 Florida and North Carolina2 ( 34 ) 
produced 46 million metric tons of phos- 
phate rock valued at almost $1.3 billion. 

Underlined numbers in parentheses re- 
fer to the items in the list of refer- 
ences preceding the appendix. 



About 20 million metric tons of phos- 
phate rock are exported annually from 
the United States. Of this total about 
17 million metric tons valued at $510 
million is exported from Florida. In 

^Florida's production data are combined 
with those of North Carolina to conceal 
the latter 's production because there 
is only one producing company in North 
Carolina. 



addition, the value of phosphate fertil- 
izers that are produced in and exported 
from Florida in 1980 is estimated to ex- 
ceed $500 million (23). 

Most of the phosphate is used for agri- 
cultural purposes, and a large agrichemi- 
cal industrial complex has grown up in 
association with the Florida phosphate 
mining activity. The bulk of the phos- 
phate rock produced in Florida is con- 
verted to phosphoric acid, which is then 
used to make various agricultural chemi- 
cal products such as ammonium phosphate, 
superphosphate, or triple superphosphate 
fertilizers. Figure 1 (p. 13) shows a 
phosphate rock processing complex. Some 
phosphate rock is smelted to produce 
elemental phosphorus, which is used in 
some inorganic chemicals and detergents, 
as well as in the manufacture of ferro- 
phosphorus. Table 1 shows national pro- 
duction figures as well as those from 
Florida and North Carolina. 

In addition to Florida's significant 
phosphate fertilizer production, uranium 
oxide (U30g) and fluorine (fluosilicic 
acid) are recovered as byproducts. Six 
companies have constructed uranium recov- 
ery facilities: four in Florida and two 
in Louisiana, The amount of U-jOg recov- 
erable from central Florida phosphate 



rock is estimated to be almost 35,000 
metric tons. This material has a poten- 
tial value of more than $3 billion ( 23 ) 
and could provide a significant portion 
of domestic requirements (31). 

Byproduct fluorine, for use in water 
fluoridation and in aluminum metal pro- 
duction, also has been recovered from 
Florida operations for many years and 
represents about 47 pet of the poten- 
tially recoverable byproduct fluorine 
from U.S. sources (14). 

ECONOMIC CONTRIBUTION ( 23 ) 

Employment 

The Florida phosphate industry plays an 
important role in the economy of the 
State. The industry had a direct employ- 
ment of 12,500 people in 1981 and was 
responsible for a total of 48,500 jobs 
(direct and indirect). In the same year 
phosphate workers earned $27 million in 
wages, which greatly exceeded the wages 
of the entire Florida citrus industry ($9 
million) . The phosphate industry also 
serves as "a major economic catalyst," 
spurring the development of numerous 
other enterprises that exist to serve the 
industry or its employees. 



TABLE 1. - Production and value of phosphate rock from Florida 
and North Carolina and the United States 

(Thousand metric tons- and thousand dollars) 





Florida and North Carolina 


United 


States 


Percent of production 


Year 


Production 


Value 


Production 


Value 


from Florida and 
North Carolina 


1981 


46,281 


1,289,366 


53,624 


1,437,986 


86.3 


1980 


47,243 


1,124,929 


54,415 


1,256,947 


86.8 


1979 


44,256 


918,555 


51,611 


1,045,655 


85.8 


1978 


43,258 


817,165 


50,037 


928,820 


86.5 


1977 


40,575 


718,393 


47,256 


821,657 


85.9 


1976 


37,690 


867,092 


44,662 


949,379 


84.4 


1975 


36,999 


1,000,352 


44,378 


1,122,184 


83.4 


1974 


33,618 


408,979 


41,533 


501,429 


80.9 


1973 


31,297 


191,654 


38,306 


238,667 


81.7 


1972 


31,019 


173,910 


37,119 


207,910 


83.6 


1971 


29,228 


167,753 


35,351 


203,828 


82.7 


1970 


28,435 


158,972 


35,217 


203,218 


80.7 



Although general wage rates In Florida 
trail the national average by 10 pet, 
wages paid to Florida phosphate workers 
exceed the national average by 17 pet. 
Most of these wage earners are concen- 
trated in Polk County, with others in 
nearby Hillsborough, Manatee, and Hardee 
Counties, and some in northern Florida, 
principally in Hamilton County. Almost 
56 pet of the workers directly employed 
by phosphate producing companies are en- 
gaged in mining and benefieiating phos- 
phate rock, with 41 pet employed in the 
production of fertilizer materials. The 
remaining 3 pet of the workers are em- 
ployed in the manufacture of inorganic 
chemicals from beneficiated phosphate 
products. 

Taxes ( 23 ) 

The total tax bill paid by the Florida 
phosphate industry in 1981 was about 
$125 million. Corporate income taxes 
have been collected in Florida since 
1972. The rate is 5 pet of the adjusted 
Federal corporate income tax minus a 
$5,900 exemption. This generated approx- 
imately $5,800,000 in tax revenue in 
1981, $3,500,000 collected directly from 
the phosphate industry and $2,300,000 
from related economic activities. 



The "sales and use" tax is Florida's 
primary source of revenue. The basic 
rate is 5 pet. The sales tax revenue 
generated by phosphate mining and 
manufacturing was over $25 million in 
1981. 

The Florida phosphate industry is also 
subject to vehicle and motor fuel taxes 
for the State of Florida. In 1981 these 
totaled $300,000. In the same year ad 
valorem property taxes paid to county 
and city governments, mostly in central 
Florida, exceeded $24 million. 

Since 1971, Florida has levied a min- 
eral severance tax based on the value 
of the phosphate rock. The tax, orig- 
inally 3 pet, was raised to 4 pet in 
1973, to 5 pet in 1975, and to 10 pet 
in 1978. Of the $100 million the phos- 
phate industry has paid in severance 
taxes , about 24 million has been refund- 
ed for reclamation work. The State of 
Florida also allows a tax credit of up 
to 20 pet of the local or county prop- 
erty tax to be applied against the sever- 
ance tax due the State. Florida col- 
lected $75,549,531 from the phosphate 
industry in 1981 in the form of severance 
taxes . 



FLORIDA PHOSPHATE RESOURCES 



Estimates of Florida's phosphate re- 
sources and the portion of these re- 
resources that is currently economic 
(reserves) have come from various sources 
and in many cases appear to be different. 
These differences are mainly due to the 
variables that are used relating to price 
assumptions and/or mining and beneficia- 
tion technology, differences in cutoff 
parameters of rock quality and quantity 
on a deposit basis, differences in the 
methodology used to assess the resources, 
and the previous lack of a universal 
technical language. However, all esti- 
mates of phosphate rock resources and re- 
serves may be correct when compared and 
analyzed using the same parameters and 
language. In this regard, the Bureau of 
Mines, using its Minerals Availability 
System (MAS), contracted a study to de- 
fine phosphate resources in Florida (43). 



The study classified the resource through 
geologic, engineering, and economic eval- 
uations of identified reserves and re- 
sources, using specific parameters for a 
minable deposit, and using the resource 
classification system developed by the 
Bureau of Mines and the U.S. Geological 
Survey (37). Hypothetical or speculative 
resources were not included. Only iden- 
tified properties (which amounted to 108) 
were evaluated; speculation on resources 
located between mining properties was not 
included. Industry participation was re- 
quested and those data submitted by in- 
dustry were used; however, some pro- 
prietary industry data were not avail- 
able for the study. Data summarized 
in table 2 show that there were 4.1 
billion short tons of phosphate rock 
recoverable at a cost of $40 per short 
ton or greater. 



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These figures can only be considered as 
part of Florida's reserve base and by no 
means should be considered as the total 
reserves and resources available to the 
industry over time. They reflect that 



portion of the resource that is being de- 
veloped or identified and formally con- 
sidered for development at a price to 
meet forecasted economic production 
requirements. 



REGULATORY FACTORS AFFECTING THE PHOSPHATE INDUSTRY 



Following the enactment in 1972 of the 
Florida Environmental Land and Water Hau- 
agement Act and the Federal Water Pollu- 
tion Control and Clean Air Acts, many 
agencies began developing specific rules 
and regulations designed to ameliorate 
the various effects related to environ- 
mental concerns. In the course of this 
development, there appears to be a con- 
siderable overlapping of responsibility 
among the agencies. Furthermore, many 
of the promulgated standards apparently 
were developed without fully considering 



the inherent costs or the technological 
ability to meet these standards. Both 
limitations must be considered in promul- 
gating regulations so that a proper bal- 
ance between mineral production and en- 
vironmental goals can be achieved. 

Table 3 lists the agencies and de- 
partments that require permits before 
phosphate mining in Florida can be ini- 
tiated. These agencies are grouped ac- 
cording to local (county), State, and 
Federal authorities. 



TABLE 3. - Permits required for phosphate mining development 



County, 



State: 

Department of Veterans and Community 
Affairs (through Regional Planning 
Council) , 

Department of Environmental Regulation 
permits , 



Zoning change. 
Master plan approval. 
Development order. 
Operating permit. 
Building permit. 



Development of regional impact. 

Air quality. 
Industrial waste water » 
Dredge and fill. 
Drainage well. 
Dam construction. 
Potable water supply. 
Sanitary waste. 

Water Management District permits Consumptive water use. 

Water well construction. 

Works of the district. 

Management and storage of surface waters, 

Department of Natural Resources Reclamation standards , 

Federal: 

Environmental Protection Agency National Pollutant Discharge Elimination 

System (NPDES) (water quality) permit. 
Air quality standards. 

Army Corps of Engineers permit Dredge and fill. 

Dam construction in waters of the United 
States, 



A major consideration in securing a 
permit prior to mine development is the 
amount of lead time an agency needs to 
review the "con^>leteness" of the per- 
mit application. Before a formal appli- 
cation is filed, it may be necessary 
for the permittee to hold one or more 
prepermitting conferences to discuss 
special problems or sensitive issues. 
Once a work plan has been approved, 
fleldwork. and baseline studies are be- 
gun for use in preparing a permit 
application. 

Upon formal submission of the completed 
application, most agencies require 30 to 
120 days for review and evaluation. As a 
part of the review process, the public is 
invited to participate in the decision- 
making process. Often modifications to 
the original application are required 
which subsequently require the services 
of consultants to support specific ele- 
ments of the application. To date, there 
is no official clearinghouse for the to- 
tal application. In many instances a 
permittee must have previously filed, or 
otherwise received approval from one 
agency, before approval from another 
agency can be granted. This often delays 
the permitting process. 

In section 380.06(6) of the Florida 
statutes, the Department of Veteran 
and Community Affairs requires the de- 
velopment of a regional impact study 
"...intended to provide information to 
local governments to assist them in mak- 
ing decisions concerning developments 
having greater than local impact." This 
application establishes the framework for 



cooperative planning between the permit- 
tee, the local government, and regional. 
State, and Federal agencies, addresses 
such basic information as air, land, and 
water ( 24 , 32) , and considers issues re- 
lated to — 

Wetlands 

Flood plains 

Vegetation and wildlife 

Historical and archeological sites 

Recreation and open space 

Socioeconomics 

Waste water management 

Drainage 

Water supply 

Solid waste 

Energy consumption 

Much of this same Information Is also 
required in EPA's Environmental Impact 
Statement, which is required by the Fed- 
eral Government pursuant to section 
102(2) (c) of Public Law 91-190. A Sup- 
plemental Information Document (SID) also 
contains technical details presented in a 
form intended to be reviewed by a non- 
technical public. Copies of these docu- 
ments are circulated to over a dozen 
State and local agencies for review and 
recommendations . 



The Florida Department of Environmental 
Regulations (DER) also regulates and is- 
sues permits concerning — 

Air 

Industrial waste water 

Dredge and fill 

Drainage wells 

Dam construction 

Potable water supply 

Sanitary water 

Each of these elements requires de- 
tailed studies to support issuances 
of the permit and must include site- 
specific plans for monitoring and/or 
abating sources of potential environmen- 
tal problems. 

The Florida Water Management Districts 
regulate surface and ground water use by 
mining companies. Specifically, consump- 
tive water and well construction permits 
are required in addition to Works of the 
District permits which govern water with- 
drawal and discharge, and construction of 
facilities owned or maintained by the 
District. 

Water supplies for a mine are also a 
concern for a mining venture. Pumping 
tests and hydrological assessment are re- 
quired to project water consumption rates 
and 'hydrological balances. Occasionally, 
recharge wells are used to recharge sur- 
ficial aquifers in the mine area. In 



these instances the quality and quantity 
of the recharge water are determined, and 
special limitations may be imposed (19). 
Table 4 summarizes average startup costs 
of environmental studies and permit ap- 
provals for operating a mine. The ground 
water study, as reported, averages 
$1,500,000 to complete. 

The Florida Department of Natural Re- 
sources regulates and monitors reclama- 
tion efforts by the raining companies. 
Each mining company submits detailed 
plans for primary and subsequent reclama- 
tion of the mine site. These plans pro- 
ject rate of mining, the sequence of each 
mining phase, and a timetable for recla- 
mation and final restoration of the post- 
mined lands. 

Approximately 5 years are necessary to 
achieve final approval for mining to be- 
gin, assuming no litigation. An actual 
permitting schedule is given in table 5. 
Once a valid permit to mine is issued, 
additional work permits must be obtained 
to construct buildings, roads, power- 
lines , draglines , and sanitary facili- 
ties. The appendix details one phos- 
phate company's permitting chronology 
from land acquisition to the final permit 
to mine. 

In summary, the phosphate mine operator 
can expect to invest approximately $4 to 
$5 million and 5 years to obtain the per- 
mits required to mine phosphate in 
Florida. Only large companies with sub- 
stantial financial resources can afford 
such significant long-term investments. 
Consequently, the Florida industry is 
composed of such firms . 



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TECHNOLOGICAL FACTORS AFFECTING THE PHOSPHATE INDUSTRY 



To fully grasp the con^)lexity of the 
total system of phosphatlc clay genera- 
tion, the geology and characteristics of 
the clays must be fully understood. A 
description of the mining and matrix 
(ore) transportation systems also is re- 
quired, since these systems initiate the 
separate of the clay from its natural 
state in the matrix, which is a mixture 
of phosphate pebbles and phosphatic sand 
dispersed in a nonphosphatic sandy clay. 

Mining of phosphate in Florida is con- 
ducted by strip mining methods. Figure 2 
illustrates a typical mine. The mining 
process may be briefly described as fol- 
lows: Each dragline excavates a series 
of parallel cuts several hundred to sev- 
eral thousand feet in length and 200 to 
300 ft wide. Overburden is cast into a 
previously mined cut, and the underlying 
matrix is exposed. The matrix is then 
mined and transferred to a slurry pit 
located aboveground within reach of the 
dragline. In the slurry pit, large water 
guns, shown in figure 3, deliver 10,000 
to 12,000 gpm at about 200 psi to break 
down the friable matrix into a slurry for 
pumping to the central benef iciation 
unit. 

Figure A shows the conventional process 
flow to illustrate the complexity of the 
benef iciation process. This process is 
separated into three distinct phases: 
sizing of pebble, washing and feed prepa-' 
ration, and flotation of concentrate 
product, A major portion of the phos- 
phate rock product from the benef iciation 
process is converted to phosphoric acid 
at the near-mine-site chemical plants. 
As part of the phosphoric acid manufac- 
turing process, byproduct phosphogypsum 
is generated ( 17 ) . 

Each phase of the mining and beneficia- 
tlon operation contributes to the genera- 
tion of phosphatic clays. Collectively, 
phosphatic clay is composed of minus 150- 
mesh particles of clay, quartz, and phos- 
phatic materials which are rejected dur- 
ing benef iciation. Generally phosphatic 
clay slurries containing 3 to 5 pet 



solids are impounded behind dikes which 
are built around mlned-out pit areas. 
Approximatly 60 pet of this material is 
stored below ground and 40 pet above 
ground level. These dikes often range in 
height from 20 to 60 ft above natural 
ground level and occupy as much as 300 to 
800 acres each. Figure 5 shows an aerial 
view of a typical settling pond. It is 
estimated that each year 2,500 acres of 
additional storage area are needed for 
phosphatic clay disposal (11). 

ISSUES ASSOCIATED WITH PHOSPHATIC 
CLAY DEWATERING 

In reviewing the issues confronting the 
phosphate industry, the management and 
storage of phosphatic clay is clearly the 
most significant technical topic affect- 
ing the industry. Another area directly 
related to phosphatic clay dewatering is 
the environmental restrictions and regu- 
latory requirements. Many of the envi- 
ronmental regulations relate indirectly 
to the handling and ultimate management 
of phosphatic clay. Total water budgets 
and dam construction standards are typi- 
cal regulatory requirements associated 
with phosphatic clay management. 

Geology and Distribution 
of Phosphatic Clays 

The central Florida phosphate district 
is located in southwestern Polk, south- 
eastern Hillsborough, northeastern Mana- 
tee, northwestern Hardee, and northwest- 
ern DeSoto Counties, with the northern 
phosphate district located in Hamilton 
and Columbia Counties, as shown in fig- 
ure 6. The Bone Valley Formation, which 
underlies part of the central district, 
is the principal source of phosphate ore 
presently being mined. However, Hawthorn 
Formation ores are mined in the northern 
district and occur in parts of Manatee, 
Hardee, and DeSoto Counties. The term 
"matrix" is colloquially used in the 
Florida phosphate mining districts for 
ores from the Bone Valley Formation and 
the Hawthorn Formation. These deposits 
are located along the southern flank of a 



13 




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Pnmory desliming h 






ISO mesh 
Minus 




' ■ 


— ►To cloy 
disposal 


isecondory deslimingh 












-j Feed sizing | 




idiaie 
ble 












{ Oewolering | 


1 Dewoteringj 








t:. 


T 


s 

\ 




> 


' 


Anionic 

■ ■/ 


reagcn 




1 Conditioning 1 

1 


1 Conditioning | 




nterm 
peb 




beneficiotion 


Coarse(plus 35 mesh) | Fine (minus 35 mesh) 








Rougher flototion 


Rougher tails 




Sulfuric oci 








' 




Rougher concentrate 
acid scrub and rinse 




—►To 






[;aIionic reo 


tailings 




gents 


disposal 




Amine flotation 




















1 

Clarification 
and refuse 


Final concentrate, 
14 by 150 mesh 



FEED PREPARATION FLOTATION 



FIGURE 4. - Conventional flowsheet for phosphate beneficiation. 








FIGURE 5, - Aerial view of typical settling ponds. 



17 




FIGURE 6. - Mnn of ohosphate-producing counties. 




FIGURE 7. - Typical cross section of the cen- 
tral Florida phosphate district. 

major structural uplift known as the 
Ocala Arch (12). Historically, the Bone 
Valley Formation as well as the minable 
portions of the Hawthorn Formation^ con- 
tain as major constituents phosphorite 
(carbonate-fluorapatite) , quartz, and 
clay fractions which are depositional 
products of marine, estuarine, and ter- 
restial sediments of Pliocene age (12). 
A typical cross section of the lithology 



is provided in figure 7, which shows a 
thin mantle of topsoil, a 10- to 20-ft 
mixture of sand-clay overburden material, 
a leach zone to 10 ft thick, and the 
5- to 20-ft-thick phosphate matrix zone. 

The difficulty of processing these de- 
posits varies with the total clay content 
of the matrix zone and the mineralogical 
composition of the associated clays. 
Figure 8 (40), a schematic representation 
of three phosphate matrices, illustrates 
quantitatively the variability of the ba- 
sic constituents of each matrix. In each 
matrix the quantities of sand, clay, wa- 
ter, and phosphate material vary to such 
an extent that each processing plant must 
be modified and uniquely designed to ac- 
commodate these variations. Consequent- 
ly, while a particular disposal system, 
i.e., one involving sand and/or clay, 
may be a solution for one processing 
plant, the volumes of sand and clay, as 
well as mineralogical composition of the 
clays, may change so as to preclude its 
use at another plant. 

Characterization of Phosphatic Clays 

The distribution of clay is widespread 
throughout the Bone Valley and Hawthorn 
Formations and occurs intimately with the 
matrix zone. Typically, the clays are 
coii^)Osed of varying amounts of montmoril- 
lonite (smectite), attapulgite (palygor- 
skite), kaolinite, illite, fine-grained 
carbonate-fluorapatite, and silt-size 
quartz (11). A study of 28 samples from 
14 processing plants in Polk County 
showed that a majority of the phosphatic 
clays also contained traces of wavellite, 
crandallite, millisite, feldspar, chert, 
dolomite, muscovite, heavy minerals, and 
other accessory minerals (18). 

Figures 9, 10, and 11 are scanning 
electron microscope photomicrographs of 
the predominant clay types found in a 
phosphatic clay, attapulgite, montmoril- 
lonite, and kaolinite. As these materi- 
als each have different settling charac- 
teristics, the complex combinations that 
occur in the natural state cause an 
almost infinite variation in settling 



18 



4.5p 
4.0 
3.5 - 
3.0- 



I2.5 

o 

uIZ.O 

d 1.5 

> 

1.0 

.5 




Note, 0.45 cu yd of 
matrix = I ton 
of product "^yP® ^ matrix 



Type A matrix 



Type C matrix 



Water 




FIGURE 8. - Comparison of ore constituents. 



characteristics of phosphatic clays. For 
example, studies (8^) have shown that 
phosphatic clays containing higher 
amounts of attapulgite settle more slowly 
initially than those containing less of 
this particular clay material. In addi- 
tion, it has recently been found by the 
Bureau of Mines that some clays are not 
fully "calcium ion exchanged." These 
clays resist dewatering by flocculation 
techniques and require special handling 
(28). Complicating matters, another 
study ( 15 ) demonstrated that the total 
solids and mineralogical content of phos- 
phatic clays in the mill feed from a sin- 
gle mine can vary hourly. These facts 
emphasize the difficulty of predicting 
settling behavior and consolidation of a 
"typical" phosphatic clay. 

These findings, along with scanning 
electron microscopic studies (7), indi- 
cate that a diagnostic determination of 



each phosphatic clay "suite" is necessary 
before a proper treatment and disposal 
system can be adopted. As a result of 
extensive data collection and experimen- 
tation, a model (4^) has been developed 
that can be used to predict settling and 
consolidation characteristics of clay 
slurries. Also, centrifuge testing of 
clay slurries has been successful in 
characterizing phosphatic clay proper- 
ties. These techniques should prove use- 
ful in determining settling and consoli- 
dation variables of a particular clay 
slurry so that maximum water recovery and 
the terminal solids-to-water ratio of a 
slurry can be predicted. 

PHOSPHOGYPSUM DISPOSAL 

Another concern associated with the 
phosphate industry is the near-site chem- 
ical plants that produce phosphoric acid. 
During processing for the manufacture 



19 




FIGURE 9. - Scanning electron photomicro- 
graph of attapulgite (X 20,000). 




FIGURE n o " Scanning electron photomicro- 
graph of kaolinite (X 20,000)„ 



FIGURE 10, - Scanning electron photomicro- 
graph of montmorillonite (X 20,000). 

of phosphoric acid, large stockpiles of 
byproduct phosphogypsum are generated. 
It has been estimated that by the year 
2000 about 1 billion tons (17) of this 
material will be stockpiled in Florida. 
To date, limited economical uses have 
been found for this material; however, 
several research groups, including the 
Bureau of Mines and the Florida Institute 
of Phosphate Research, are currently 
studying, testing, and evaluating the 
potential uses of phosphogypsum. 

MINING OF WETLANDS 

Environmental groups and some regula- 
tory agencies are particularly concerned 
about wetlands , which represent a signif- 
icant portion of the total land surface 
in Florida and may contain a significant 
amount of the total phosphate resources. 
Marshes, both intermittent and permanent, 
as well as swamps and extensive parts of 
river flood plains fall into the wetlands 
classification. These areas are of value 
for wildlife habitat and surface water 
retention. Florida contains over 20 pet 



20 



by urbanization, 
and agriculture 



of the Nation's total remaining wet- 
lands, which have been reduced primarily 

highway construction, 
(36)» Consequently, 
proposals to mine these areas often meet 
with strong opposition. Many of these 
areas contain phosphate reserves that 
could be mined after which the land 
could be reclaimed to a wetland ecosystem 
using modified mining and reclamation 
practices. 

Industry wetlands reclamation research 
projects are considered unproven technol- 
ogy. Dredge and fill permits are being 
approved by the State only for areas that 
have been functionally modified by agri- 
culture and other land use activities. 
To date, no standards have been developed 
that would allow mining of all wetland 
types. 



LAND RECLAMATION 

The general reclamation of phosphate 
lands using only sand tailings and 
overburden spoil is relatively easy to 
achieve. About 40 pet of the mined 
land is available for this typed of 
reclamation, which may result in a land 
and lakes configuration as shown in 
figure 12. 

The extended periods of time over which 
clay settling ponds remain active and the 
extent of areas occupied by these unre- 
claimed sites have caused officials to 
delay permission to construct fu- 
ture phosphatic clay storage areas. As a 
result of such delays, Industry's efforts 
to investigate other solutions to the 
clay disposal management have increased. 



^<»^a— ^^ 



■j»' 





FIGURE 12. - Phosphate land reclamation in land and lakes configuration. 



21 



STATUS OF DEWATERING TECHNOLOGY 



Since the early days of phosphate min- 
ing, phosphatlc clays have been generated 
In the mining process. In 1891 a pro- 
duction rate of 112,000 metric tons of 
phosphate rock per year did not create a 
serious phosphatlc clay management prob- 
lem, especially when this material was 
confined to sparsely populated areas. As 
phosphate production In Florida Increased 
and mining and benef Iclatlon technolgles 
changed, the need for expanded plant fa- 
cilities and for the innovative handling 
of overburden, sand tailings, and phos- 
phatlc clays led to the development of 
the present-day clay storage areas. 

CONVENTIONAL SETTLING PROCESS 

The conventional settling pond has been 
the most widely used process for dispos- 
ing of phosphatlc clays. This process 
is simple and direct in that 20- to 60- 
ft-high dikes are constructed around 
areas 300 to 800 acres in extent. These 
impoundments are filled with 3 to 5 pet 
plant clay which exits the plant at 
to 80,000 gpm. Figure 13 shows 
being discharged into a typical 
Most settling ponds have 1- to 
storage capacities and are used 
with other ponds to allow 
quiescent settling. When 



20,000 
clays 
area. 
2-year 
alternately 
periods of 
mlned-out cuts are used for storage, the 
clays are directed through a network of 
windrows cast from overburden and/or 
spoil that act as baffles to allow natu- 
ral settling. 

During natural settling, most clays 
consolidate to 12 to 15 pet solids within 
3 to 30 months (_5 , 7^) , resulting in a 
material having a mudlike consistency. 
At this stage, most of the surface water 
is drained from the settled material, 
which allows the solids to desiccate 
and subsequently form an Impervious 
crust. This crust seals the top portion 
of the clay mass and offers some bear- 
ing strength. Frequently sand tailings 
and/or overburden material are used to 
cap the clays so that the added weight 
of the cap can exert vertical stresses 
on the clays below to promote further 
consolidation and compaction. Because of 



the slow consolidation rate of the clays, 
this process may require 5 to 15 years 
before reclamation of the storage area 
can be totally completed. The ultimate 
percent clay solids required to attain 
original elevation storage ranges from 20 
to 44 and averages 35. This wide range 
is due to variation in the clay content 
of the matrix, as well as the clay miner- 
alogy. Figure 14 shows the process flow 
of conventional clay disposal. 

The main advantage to conventional set- 
tling is that the Impoundments also act 
as reservoirs for process water. Without 
clay settling areas , large water reser- 
voirs would be necessary to provide 
enough water for benef iclatlon and other 
process needs. Other advantages of con- 
ventional settling follow — 

• The areal extent of the Impoundments 
allows rainfall to be collected. 

• The procedure serves to collect and 
concentrate residual phosphate 
values . 

• The procedure is familiar to the 
industry. 

• Based on present technology, it is 
the most cost effective procedure. 

• Surface clay storage area is minimal. 

The major concern regarding this pro- 
cess has been the possibility of a break 
in the dikes surrounding the phosphatlc 
clays; however, since the State's revised 
dam construction law of 1972, there have 
been no dam breaks. Other disadvantages 
include — 

• Slow rates of initial settling and 
subsequent consolidation of the 
terminal solids. 

• Large areas of unreclaimed land 
occupied by phosphatlc clays. 

• Limited land uses of reclaimed 
storage areas. 



22 








FIGURE 13. - Phosphatic clays being discharged into a typical settling area. 



Phosphatic clays 



(37o to 5% solids) 



^ 




Initial settling area 




Active settling area 

FIGURE 14. - Conventional clay disposal process. 



Recycle 



water 



23 



Recently, State regulatory agencies 
have proposed that phosphatlc clays 
should be returned to the mine cuts and 
that reclamation of these areas should 
achieve an approximation of the original 
surface contour. In theory, below-ground 
storage of the phosphatic clays, sur- 
rounded by temporary low-profile dams, 
would virtually eliminate dam failure. 

Another method suggests building a sta- 
ble structure of clay solids by incorpor- 
ating additives such as phosphogypsum, 
lime, or other materials, which would 
tend to stabilize the clay mass. This 
technique would have the effect of chang- 
ing a fluidized mass to a semiplastic 
relatively incapable of fluid movement. 

The bulk of the phosphatic clay parti- 
cles is submicrometer-sized material that 
entraps and holds large quantities of 
process water. Often during processing, 
these colloidal-sized particles retain 
up to 30 times more water than was pres- 
ent in the initial matrix state (16), 
As a general rule, 3 to 4 tons of water 
is retained in phosphatic clays for each 
ton of phosphate produced. Consequently, 
readily available makeup water is needed 
to supplement any recycle water used in 
processing new matrix. Some of the make- 
up process water is withdrawn from deep- 
well aquifers, which also are used to 
support the citrus, farming, and other 
industrial processing demands in the 
area. As an example of consumptive wa- 
ter use, a conventional 2- to 3-million- 
ton-per-year phosphate processing plant 
will generate clay slurries at the rate 
of 20,000 to 80,000 gpm at 3- to 5-pct 
clay solids content. A typical phosphate 
plant will ultimately recover and reuse 
approximately 90 pet of its process water 
(40), However, much of the initial 
slurry water is not immediately available 
because of the slow settling character- 
istics of the clay solids. To minimize 
localized drawdown of supply wells , sev- 
eral phosphate companies are using re- 
charge wells as illustrated in figure 15, 
These wells are strategically located 
so as to collect and transmit surficial 



water from the upper phreatic levels to 
subterranean aquifers. In using this 
method and by recycling decanted water 
from water storage areas, water conserva- 
tion is practiced. 

In reviewing the research efforts by 
industry. State and Federal Governments, 
and universities, it should be emphasized 
that, collectively, many years and mil- 
lions of dollars have been invested in 
seeking ways of dewatering phosphatic 
clays. Studies are continuing to update 
state-of-the-art techniques for effective 
dewatering, but to date no "universal" 
solution has been demonstrated that will 
eliminate initial settling areas. 

In reviewing solutions to the phos- 
phatic clay management problem, many 
techniques have been investigated ( 20 , 
33) , Listed below are some of the tech- 
niques that have been evaluated and stud- 
ied in laboratory tests: 

Admixing with coarse material 

Biological aggregation 

Cent rifugat ion 

Chemical solidification 

Flocculation 

Mechanical thickeners 

Electric field 

Evapotranspiration 

Filtration 

Elect roosmos is 

Freeze-thaw 

Magnetic separation 

Seepage dewatering 

Reverse osmosis 



24 







Recharge well 






"N 



JTfc,*t— '-t*CS>fV—V 



i^Water table- 







Monitoring wellsx ^l 
Floridan, li^' Shallow 



/ 



M 



~t^^.^=*^ .^— ^--* , -W / 1^ •.■^VN^rr" , noriaan. 1^ bnaiiow -j u 




FIGURE 15. - Recharge well system. 



Recently, several research efforts have 
been translated from basic laboratory- 
scale to production-scale processes. 
Each of the processes was proposed for 
general application; however, field oper- 
ating conditions, plant facilities, water 
budgets, ore cony)osition, etc., required 
site-specific application. Several pro- 
cesses and field tests using flocculants, 
thickeners, and admixing processes to 
accomplish rapid dewatering are reviewed. 

BREWSTER PHOSPHATES' 
SANIHSPRAYING PROCESS 

In the sand-spraying process, as de- 
veloped by Brewster Phosphates, sand 



tailings are sprayed over a layer of pre- 
consolidated clays so as to impose addi- 
tional stresses on the clays, creating 
secondary dewatering. In using this 
method, as shown in figure 16, the clays 
are permitted to settle naturally to a 
10- to 15-pct solids content. At this 
stage the clays develop a gel-like struc- 
ture which inhibits the further release 
of interstitial water. Sand is then 
sprayed over the clays in an effort to 
release additional water via vertical 
channeling generated by the settling sand 
particles. It has been estimated that 
once equilibrium is established, the 
sands and clays will form a cohesive mass 
of 50 to 70 pet solids (6). 



25 



Standby 



Phosphatic clays 



(3% to 5% solids) 




Initial clay settling 



"^1 



M_i.i I 




Tailing sands (30% solids) 

— s~* * 1 1. i i 



Disposal area :^r 

Sand capping 



Recycle 



water 



FIGURE 16. - Sand-spraying process for cloy disposal. 



Phospha tic clays _^ 



(3% to5 7o 

solids) 



Tailing sands 



(30% solids) 



Alternate 
> holding pond 




Initial settling pond 



Initial clay settling 



I I I 1 I 





Sand application to cap 
settled clay at 12% to 
15 % solids 



Second application of 
clay, 3 % to 5 % solids 



Recycle 
water 

FIGURE 17. - Sandwich construction for sand-clay disposal process. 



26 



A variation of the sand-spraying pro- 
cess (^, _38) is the "sandwich" technique 
developed by USS Agri-Chem and the Massa- 
chusetts Institute of Technology, shown 
in figure 17. In this process, alternat- 
ing layers of sand tailings and phosphat- 
ic clays are used to cap and expel inter- 
stitial water from the prethickened clays 
structure by virtue of superimposed 
stresses. The added weight of each sub- 
sequent layer "squeezes" the lower lay- 
ers, thus forcing further dewatering. 
The sand tailings, in this case, also 
provide lateral paths for water movement 
from the clays to preselected discharge 
points. 

The advantage to these admixture pro- 
cesses is the ability to dispose of both 
the sand and clays in the same disposal 
site while creating a relatively stable 
mass. The resulting sand-clay mixture 
seems to provide a suitable structure and 
favorable growth medium for sustaining 
revegetation. 

The most significant disadvantage to 
the technique seems to be the logistics 
of providing the sand required for dis- 



posal, A proper sand-clay ratio must be 
maintained and is largely dependent on 
the composition of the processed miatrlx. 
Other disadvantages include 

• Difficulty of proper clay-capping 
techniques, 

• Creation of "mud waves." 

• Segregation of sand particles in the 
resulting mixture, 

• "Turn-around" time for proper clay 
thickening. 

• Total volume of sand and prethickened 
clays may not achieve near-original- 
contour reclamation, 

INTERNATIONAL MINERALS AND CHEMICALS 
CORP. PROCESS 

The Initial dredge mix process as de- 
veloped by the International Minerals and 
Chemicals Corp, (IMC) begins when precon- 
solldated clays are dredged from Initial 
holding ponds and mixed with tailings 
sands (16). This admixture of clay and 



Tailing sand (30 % solids) Cyclone 

Q — ^ ^ — ' 

^ Dewotered 

sands 




Holding 
pond-dredging 




Prethickened 
clays 



Recycle 



water 



Thickened clays 




Disposal area 



FIGURE 18. - International Minerals and Chemicals Corp. process for cloy disposal. 



27 



tailings sands Is slurried and pumped to 
mlned-out cuts at approximately 32 pet 
total solids. The flowsheet In figure 18 
Illustrates the procedure wherein pre- 
thlckened clays at 15 to 18 pet solids 
are dredged from the Initial holding 
ponds, slurried with dewatered tailings 
sands, and pumped to a settling area for 
final consolidation. 



floes that will not reslurry readily and 
that will cause rapid settling and dewa- 
tering of phosphatic clays. Frequently, 
successful flocculating reagents evalu- 
ated in the laboratory on a specific clay 
proved unpredictable in field tests owing 
to the variables encountered in the field 
test conditions. Among these variables 
(39) are — 



Initial work conducted by IMC indicated 
that sand-clay admixtures alone will not 
provide sufficient compaction stress for 
ultimate ground level storage. There- 
fore, the process was modified to elimi- 
nate the sand and is now referred to as 
the dredge process. The dredge process 
still requires an initial settling area 
to thicken the primary clays to 15 to 18 
pet clay solids, which are then dredged 
from the initial settling area and pumped 
into mined areas for final dewatering and 
storage. The clays are then capped with 
6 to 10 ft of available sand tailings 
supplemented by overburden. It is re- 
ported that after 5 to 8 years the clays 
will consolidate to 34 to 40 pet solids. 
The dredge process capping procedure is 
a promising technique, and the company 
is continuing its research efforts to 
determine its technical and economic 
feasibility. 

Both processes require staging of ini- 
tial holding areas so that unhindered 
settling can occur. Once the Initial 
settling is completed and the product 
dredged, the impoundment site can be re- 
used. Various options are available 
which use flocculation and/or commercial 
thickeners to accomplish initial set- 
tling, which ultimately shortens initial 
settling time. 

FLOCCULATION 

Flocculation is a technique in which 
discrete, colloidal-sized particles are 
agglomerated by an appropriate reagent 
and, as a result, settle out of suspen- 
sion (22). Hundreds of commercial floc- 
culating reagents have been tested (39) , 
singly or in combination with others, in 
an effort to select a flocculant that 
will result in the formation of stable 



Clay mineralogy 

Age of the clay slurries 

Method of flocculant introduction 

Dilution of the clay slurries 

pH of the slurry 

Mixing shear 

Conditioning and contact time 

One of the earlier flocculation demon- 
stration tests was conducted in January 
1973 at the Rockland Mine, Ft. Meade, 
Fla, Representatives of Andco, Inc. , 
demonstrated a process that involved pre- 
treating tailings sands with a suite of 
proprietary flocculants that acted as a 
collector for the clay particles. The 
process, which included filtration of 
the solids, produced a dewatered materi- 
al containing 65 pet total solids. The 
capacity of the unit, however, was a 
limiting factor, and scale-up to commer- 
cial application was considered to be 
impractical (7^, 9^) . 

Although flocculation appears to be an 
acceptable method for dewatering phos- 
phatic clays, the reuse of reclaimed 
water in froth flotation circuits may 
affect separation efficiency. Recent 
studies ( 16 , 26-27) that tested and eval- 
uated several of the more effective floc- 
culants indicated that both the fatty 
acid and amine flotation circuits were 
affected by additions of 1 to 100 ppm of 
residual flocculants. The fatty acid 
circuit was more seriously affected in 
both recovery and concentrate grade than 
was the amine flotation circuit. 



28 



Rotary Screen Process 

The Bureau of Mines is studying a de- 
watering technique for phosphatic clay 
that uses a flocculating reagent, poly- 
ethylene oxide (PEO) (25). This floccu- 
lant forms strong, stable floes, which 
can be partially dewatered on a static 
screen and further dewatered on a rotary 
screen in a matter of minutes. Using 
this technique, illustrated in figure 19, 
a field test unit (FTU) was operated at 
Estech Chemical Co.'s Silver City Mine 
and Occidental Chemical Co.'s Suwannee 
River Mine. Consolidated phosphatic clay 
material containing up to 24 pet clay 
solids was produced when feed slurries 
of 3 to 5 pet clay solids were treated. 
Pit tests indicate that products con- 
taining greater than 30 pet clay solids 



can be achieved in several months . The 
technique is not dependent on sand or 
overburden materials to achieve a high 
initial solids content. Thus, by not 
diluting the phosphatic clays, the poten- 
tial for future recovery of their con- 
tained values holds promise. 

Advantages to this process appear to be 
the in-line ability of the system, rapid 
"at-the-plant" dewatering capability, and 
the unique ability of the PEO-dewatered 
clay solids not to reslurry readily. 
Another potential advantage is that in- 
dividual process units can be operated 
either in tandem or independently. The 
Bureau is currently constructing a proto- 
type unit to be used in a cooperative ef- 
fort at Agrico Chemical Co.'s Fort Green 
mine in Polk County. 



Plant 




Phosphatic 
clays 



/-Flocculant 
i-< (PEO) 



Hydrosieve 



Mixing tank 



Recycle 
water to plant 





Warer 



Phosphatic^ 
clay solids 



Rotary screen 



Water 



Recycle 
water 



Phosphatic 
clay solids 

r^ 24% 
to mine cuts 



y/zMwwvMV'v 




Disposal area 



FIGURE 19. - Rotary screen process for clay disposal. 



29 



Gardlnler, Inc. , Process 

The Gardinier process is a proprietary 
technique. Company officials report that 
phosphatic clays from the conventional 
benef iciation plant enter the system and 
are mixed with a flocculating agent. 
"Water is then removed from the clays in 
two stages in the Clariflux thickeners" 
(13). Thickened solids leaving the Clar- 
iflux unit consist of 12 to 15 pet clay 
solids which are then mixed with sand 
tailings and pumped to a "super floccula- 
tion" thickener located at the disposal 
site. At this stage additional floccu- 
lant is added to the mixture » causing 
large floes to form. Upon settling for 
approximately 24 hours, the floe concen- 
trates to 25 pet total solids. It is re- 
ported that dewatering will continue in 
the prepared cuts and the agglomerate 
mixture will reach terminal total solids 
of 27 to 32 pet within a few weeks. 

Specific research data regarding the 
process are limited since testing is not 
complete. Figure 20 illustrates the pro- 
posed process, which will undergo exten- 
sive testing to evaluate scale-up parame- 
ters. The reported advantages of this 
process are the rapid dewatering of the 
clay solids and the ability for this 
material to be stored in or near natural 



ground level elevations with 
dams. 



low-level 



Estech General Chemical Corp. Process 

The Estech process (2, 21), shown in 
figure 21, incorporates the use of an 
Enviro-clear thickener. Phosphatic clays 
are mixed with dewatered tailings sands 
and a suitable flocculant in a surge 
tank. After conditioning, the solids are 
injected into the sludge bed of the 
thickener. In the sludge bed the free- 
settling zone of the thickener is elimi- 
nated. The admixture flows horizontally 
through the active sludge bed at a con- 
trolled velocity, while densifying and 
promoting additional agglomeration. In 
small-scale tests Estech has reported 
achieving products containing 32 pet to- 
tal solids. 

The major advantage of this process is 
reportedly its adaptability to rapidly 
settle sand-clay admixtures, thus elimi- 
nating the need for initial holding 
ponds . 

REVIEW OF DEWATERING RESEARCH 

Over the past 20 years many methods to 
dewater phosphatic clays have been inves- 
tigated, so that the clays as well as 



Phosphatic 

clays 

% to 5 

solids) 



clavs -. ' Clarified ' , 

(37o to 57 Flocculant water Flocculant 



1[ 



♦ 



I Clariflux 
1 thickness 




Thickened 



Pump 



Pump solids 

I Tailing sands 



Recycled water 




r^ 



Super — i»»«==\H'"Ty;t=x\^/'==»^ 
flocculation 




Disposal areas 
Sand base 



\ 




FIGURE 20. - Gardinier, Inc., process for clay disposal. 



30 



Phosphatic clays 



(37o to 5% solids) 

Tailing Cyclone 

T^^ 

sands 

Dewatered 

sand , 



Thickener 




-►Recycle water 



Surge tank 



Flocculant 



Thickene d 
"S solids 




Disposal area 

FIGURE 21. - Estech General Chemical Corp. process for clay disposal. 



sand tailing could be returned to the 
mine cuts, to achieve a reduction in 
dammed impoundments. By reaching this 
goal, approximate original surface con- 
tours may be achieved and aesthetic use- 
ful landforms created. Since 1972, co- 
operative research between Federal and 
State Governments and the Florida phos- 
phate industry has been extensive and has 
led to present phosphatic clay management 
efforts. 

Present efforts can be broadly cate- 
gorized in the following two systems: 

1. Conventional settling 

a. With sand admixture 

b. Without sand admixture 

c. With sand or overburden cap 



2. Flocculation 

a. With sand admixture 

b. Without sand admixture 

c. With sand or overburden cap 

Owing to wide variations in clay con- 
tent of the matrix and clay mineralogy, 
each dewatering system seems to have 
site specific applications. Presently, 
other than conventional settling without 
variations and the site-specific sand- 
spraying process, the remaining systems 
should be considered for continuing re- 
search. If the present extensive re- 
search effort is maintained, based on the 
progress of the past several years, solu- 
tions to many of the site-specific phos- 
phatic clay dewatering problems may be 
achieved. 



PHOSPHATE LAND RECLAMATION (41-43) 



Prior to July 1, 1971, the reclamation 
of mined-out phosphate lands was done on 
a voluntary basis, largely at the discre- 
tion of the industry. On that date a 5- 
pct severance tax was levied by the State 
to encourage reclamation of previously 
disturbed phosphate lands. Fifty percent 
of this tax was credited to the general 
revenue fund of the State and 50% to a 
land reclamation trust fund. However, 



shortly after being passed, this tax was 
amended in lieu of the following tax 
rates: 

Through June 30, 1973 — 3 pet of value 
of severed mineral. 

July 1, 1973~June 30, 1975—4 pet of 
value of severed mineral. 



31 



On lands unreclaimed prior to July 1, 
1975, the taxpayer (company) was entitled 
to a refund from the reclamation trust 
fund for reclamation costs of such lands 
not to exceed 50 pet of the tax paid pre- 
viously by the taxpayer. These lands 
must have been reclaimed by a plan ap- 
proved by the Department of Natural 
Resources. 

On July 1, 1975, the State required 
mandatory reclamation of all lands dis- 
turbed by a mining company and increased 
the severance tax to 5 pet. In 1977, the 
severance tax was increased to 10 pet of 
the established value of the mineral 
at the point of severance while reducing 
the rebate to 25 pet of the tax. This 
held constant the monies available for 
reclamation costs on land disturbed prior 
to July 1, 1975, and filed for before 
July 1, 1977. 



the severance 
following (30): 



tax reflected in the 



1. Termination of the phosphate sever- 
ance tax contributions to the Land Recla- 
mation Trust Fund after July 1, 1978. 
This modification means there will be no 
refunds available for reclamation of 
lands mined for phosphate after the cur- 
rent funds are expended. 

2. Creation of a new trust fund, the 
Nonmandatory Land Reclamation Trust Fund, 
which each year is to receive 20 pet of 
the excise tax collected from July 1 , 
1978, to July 1, 1983, on the severance 
of phosphate rock. This modification 
creates a fund of approximately $40 mil- 
lion to be used as an economic incentive 
for the reclamation of lands mined or 
disturbed prior to July 1, 1975 (the date 
after which reclamation is mandatory). 



The 1977 Florida Legislature also cre- 
ated a Phosphate Land Reclamation Commis- 
sion to classify and inventory all lands 
disturbed by phosphate mining prior to 
1975. Table 6 shows the acreage utiliza- 
tion and the average reclamation costs 
for reclaiming the various parcels. The 
total acreage reported takes into account 
lands that are not being reclaimed under 
existing standards (40-43). 

The 1978 Florida Legislature exten- 
sively amended Chapter 211, Part II, 
Florida Statutes in response to the 
recommendations of the Phosphate Land 
Reclamation Study Commission. The basic 
change enacted was a redistribution of 



3. Creation of a new trust fund, the 
Phosphate Research Trust Fund, which is 
to receive 5 pet of the excise tax col- 
lected annually on the severance of phos- 
phate rock. This modification estab- 
lished a permanent funding base for the 
Florida Institute of Phosphate Research. 

4. Reduction of the excise tax levied 
on the severance of phosphate rock from 
10 to 8 pet will occur on July 1, 1983, 
unless additional funding of the Nonman- 
datory Land Reclamation Trust Fund is 
approved by law. 

The implementation of the Nonmandatory 
Land Reclamation Trust Fund to provide 



TABLE 6. - Reclamation cost summary for all evaluated parcels 



Land type 


Acres 


Approximate 
reclamation 


Estimated 
reclamation 


Percent of 
total estimated 






cost per acre, 
thousands 


cost, millions 


reclamation cost 


Clay settling areas 

Mined— out areas 


59,501 

33,474 

7,853 

5,558 

1,784 


$2.1 

1.0 

.6 

1.3 

2.5 


$125.0 

33.5 

4.7 

7.4 

4.4 


71.4 
19.1 


Hydraulically mined areas. 

Sand tailings areas 

Other areas ............... 


2.7 
4.2 
2.5 






Total 


108,170 


1.6 


175.0 


199.9 


iDrxa.Q nr»^ ^^>^n^ inn . flfl Kc-a 


iiao f\i- rr\ 


iinAi ntr 







32 



economic Incentive for the reclamation 
of lands mined or disturbed by phos- 
phate mining prior to July 1, 1975, is 
conditional upon the development of a 
master reclamation plan by the Depart- 
ment of Natural Resources which will 
provide guidelines for the reclamation 
of said lands. The Department of Natural 



Resources is being aided by a specially 
created Land Use Advisory Committee, 
which is assigning priorities to the 
kinds and descriptions of lands to be re- 
claimed and designating the land uses 
that would best serve the public 
interest. 



SUMMARY 



Five problem areas affecting the Flor- 
ida phosphate industry's ability to meet 
national mineral requirements in a timely 
manner were identified: (1) phosphatic 
clay management, (2) regulatory and en- 
vironmental constraints, (3) mining of 
wetlands, (4) reclamation of disturbed 
lands, and (5) consumptive water usage. 

In reviewing these problems and the 
extensive research efforts conducted 
through the years, the single most sig- 
nificant technical problem identified is 
that of phosphatic clay dewatering. For 
years the phosphate producers worked in- 
dependently within the framework of the 
company entity, where often research in- 
formation was treated in a proprietary 
manner. However, it was soon apparent 
that phosphatic clay management was an 
industrywide problem that required the 
collective efforts of many specialized 
disciplines in fields such as physical 
chemistry, mineralogy, soil engineering, 
and equipment design. Consequently, in- 
dustry enlisted the services of State, 
Federal, and university researchers in ao 
effort to resolve this problem. 

In 1972 a major thrust was initiated 
toward resolving the dewatering problem 
when the Bureau of Mines and the phos- 
phate industry entered into a cooperative 
research program. Since then work has 
advanced from early laboratory theory to 
scaled-up field operations. Although 
much has been accomplished, no full-scale 
universal dewatering method has been 
proven that works equally well on all 
phosphatic clays, and site-specificity 
factors must be considered in selecting 
the most appropriate technology. In gen- 
eral, the flocculation processes of clay 
dewatering technology indicate that de- 
watering of clays to 24 to 32 pet solids 



can be achieved in a relatively short 
period. The dredge-capping process is 
also a promising developing technology in 
which total below-ground storage may be 
achieved. These developing technologies 
do not preclude the use of initial clay 
settling ponds to supplement the proposed 
management systems. Each proposed clay 
management system is still uniquely de- 
pendent on — 

• Amount of clay in the matrix zone. 

• Mineralogy and chemical composition 
of the clays. 

• Amount of sand associated with the 
matrix. 

• Water associated with the matrix. 

• Volume of available below-ground 
storage (collective volume of 
overburden and matrix zones). 

Although most disposal methods permit 
more rapid reclamation of clay storage 
areas, additional "external" stresses 
must be placed on consolidated clays to 
achieve the final stages of dewatering 
and stability of the clay areas. 

Although consumptive water use, land 
reclamation, and phosphogypsum storage 
all have some environmental impacts, they 
do not pose any immediate barriers to 
phosphate development. The clay manage- 
ment problem is critical and both it and 
wetlands reclamation problems are under 
continuing research by government and in- 
dustry. That research represents the 
best single hope for a solution that can 
make phosphate development and environ- 
mental concerns wholly compatible. 



33 



REFERENCES 



1. Amax, Inc. Current Permitting 
Requirements Affecting New and Exist- 
ing Florida Phosphate Mines. Pres. to 
State of Florida legislative committee. 
Mar. 18, 1981, 48 pp.; available upon 
request from the Tuscaloosa Research 
Center, Bureau of Mines, P.O. Box L, 
University, AL 35486. 

2. Barreiro, L. J., R, D. Austin, and 
A. P. Kouloheris. Compaction of Slimes 
and Sand Tailings by the Enviro-clear 
Thickener. Pres. at Phosphatic Clays 
Project Seminar, Jan. 26, 1977, 15 pp.; 
available upon request from the Tusca- 
loosa Research Center, Bureau of Mines, 
P.O. Box L, University, AL 35486. 

3. Boyle, J. R. , and C. W. Hendry, Jr. 
The Mineral Industry of Florida. BuMines 
Minerals Yearbook 1978-79, v. 2, 1981, 
pp. 134-142. 

4. Bromwell Engineering Co. Analysis 
and Prediction of Phosphatic Clay 
Consolidation — Implementation Package . 
BROM-79-105, March 1979, 52 pp.; avail- 
able upon request from the Tuscaloosa 
Research Center, Bureau of Mines, P.O. 
Box L, University, AL 35486. 

5. Bromwell, L. G. Progress Report: 
Florida Phosphatic Clays Research Proj- 
ect, January- June 1976. July 1976, 
27 pp.; available upon request from the 
Tuscaloosa Research Center, Bureau of 
Mines, P.O. Box L, University, AL 35486. 



6. 



General Report for Session 



IV of Specialty Conference — Geotechni- 
cal Practices for Disposal of Solid 
Waste Materials. Geotechnical Engineer- 
ing Div., ASCE, June 13-15, 1977, 37 pp.; 
available upon request from the Tusca- 
loosa Research Center, Bureau of Mines, 
P.O. Box L, University, AL 35486. 



7. 



Progress Report: Florida 



Phosphatic Clays Research Project. An- 
nual Report, 1973, 215 pp.; available 
upon request from the Tuscaloosa Research 
Center, Bureau of Mines, P.O. Box L, Uni- 
versity, AL 35486. 



8. Bromwell, L. G. Progress Report: 
Florida Phosphatic Clays Research Proj- 
ect. July-December 1974, 47 pp.; avail- 
able upon request from the Tuscaloosa 
Research Center, Bureau of Mines, P.O. 
Box L, University, AL 35486. 



9. 



Progress Report: Florida 



Phosphatic Clays Research Project. An- 
nual Report, 1975 (January 1976), 177 
pp.; available upon request from the Tus- 
caloosa Research Center, Bureau of Mines, 
P.O. Box L, University, AL 35486. 

10. Bromwell, L. G. , T. P. Oxford, and 
N. R. Greenwood. Economic Evaluation of 
Alternate Clay Disposal Processes. April 
1978, 38 pp.; available upon request from 
the Tuscaloosa Research Center, Bureau of 
Mines, P.O. Box L, University, AL 35486. 

11. Environmental Science and Technol- 
ogy. Those Nasty Phosphatic Clay Ponds. 
V. 8, April 1974, pp. 312-313. 

12. Fountain, R. C. , J. P. Bernardi, 
M. E. Zeller, C. H. Gardner, and T. M. 
Gunn. Field Trip Guidebook — The Central 
Florida Phosphate District. 7th Forum on 
Geology of Industrial Minerals, Interna- 
tional Minerals and Chemical Corp. , Brad- 
ley Junction, Fla. , Apr. 30, 1971, 41 
pp.; available upon request from the Tus- 
caloosa Research Center, Bureau of Mines, 
P.O. Box L, University, AL 35486. 

13. Gardinier, Inc. Clariflux- 
Superf locculation Process Method for 
Treatment and Disposal of Phosphatic 
Slimes. April 1981, 8 pp.; available 
upon request from the Tuscaloosa Research 
Center, Bureau of Mines, P.O. Box L, Uni- 
versity, AL 35486. 

14. Johnson, R. C, J. W. Sweeney, and 
W. C. Lorenz, Economic Availability of 
Byproduct Fluorine in the United States 
(In Two Sections) 1. Utilization of By- 
product Fluosilicic Acid in Manufacture 
of Aluminum Fluoride. 2. Utilization in 
the Manufacture of Calcium Fluoride. Bu- 
Mines IC 8566, 1973, 97 pp. 



34 



15. Laraont, W. E., J. T. McLendon, 

L. W. Clements, Jr., and I. L. Feld. 

Characterization of Florida Phosphate 

Slimes. BuMines RI 8089, 1975, 24 pp. 



24. Rhodes, R. M. DRI's and Florida's 
Land Development Policies. Florida 
Environmental and Urban Issues, v. 2, No. 
1, January-February 1975, pp. 5-16. 



16. Lawver, J. E. Progress Report 
Six: IMC-Agri co-Mobil Slime Consolida- 
tion and Land Reclamation Study. IMC, 
Bartow, FL, Feb. 19, 1982, 141 pp.; 
available upon request from the Tusca- 
loosa Research Center, Bureau of Mines, 
P.O. Box L, University, AL 35486. 

17. May, A., and J. W. Sweeney. As- 
sessment of Environmental Impacts Associ- 
ated With Phosphogypsum in Florida. Bu- 
Mines RI 8639, 1982, 19 pp. 

18. McConnell, G. L. Mineral Varia- 
tions in Phosphatic Slimes. M.S. Thesis, 
Univ. of South Florida, Tampa, FL, 1973, 
65 pp. 

19. Moudgil, B.M. Mined Land Reclama- 
tion by the Florida Phosphate Industry. 
Pres. at SME meeting, Salt Lake City, 
Utah, Sept. 10-12, 1975, SME Preprint 75- 
AO-325, 19 pp. 

20. Moudgil, B. M. , T. P. Oxford, 
E. D. Whitney, and G. Y. Onoda. Field 
Test of a Seepage Technique for Dewater- 
ing Waste Phosphatic Clays. Min. Eng. , 
V. 34, No. 4, March 1979, pp. 297-301. 

21. M. S. French Co., Inc. The 
Enviro-clear Clarif ier/Thickener. Gen- 
eral Catalog No. EC-76, 38 pp. 

22. Onoda, G. Y. , Jr., D. M. Deason, 
and R. M. Chhatre. Flocculation and Dis- 
persion Phenomena Affecting Phosphate 
Slime Dewatering. Proc. Internat. Symp. 
Fine Particles Processing, AIME, Las 
Vegas, Nev., Feb. 24-28, 1980 (pub. as 
Fine Particles Processing), pp. 1000- 
1011. 

23. Opyrchal, A. M. and K-L. Wang. 
Economic Significance of the Florida 
Phosphate Industry: An Input-Output 
(I-O) Analysis. BuMines IC 8850, 1981, 
62 pp. 



25. Scheiner, B. J., A. G. Smelley, 
and D. R. Brooks. Large-Scale Dewater- 
ing of Phosphate Clay Waste From Cen- 
tral Florida. BuMines RI 8611, 1982, 
11 pp. 

26. Smelley, A. G. , and B. J, 
Scheiner. Synergism in Polyethylene Ox- 
ide Dewatering of Phosphatic Clay Waste. 
BuMines RI 8436, 1980, 18 pp. 

27. Smelley, A. G. , B. J. Scheiner, 
and J. R. Zatko. Dewatering of Indus- 
trial Clay Wastes. BuMines RI 8498, 
1980, 13 pp. 

28. Stanley, D. A. Effect of Ion Ex- 
change on Dewatering Phosphate Clay Waste 
With Polyethylene Oxide. Proc. Progress 
In The Dewatering of Fine Particles 
Conf., Univ. of Alabama, Tuscaloosa, AL, 
Apr. 1-2, 1981, 13 pp. 

29. Stowasser, W. F. Phosphate Rock, 
Ch. in Mineral Facts and Problems. Bu- 
Mines Bull. 671, 1981, pp. 663-683. 

30. Sweeney, J. W. , and C. W. Hendry, 
Jr. Minerals in the Economy of Florida. 
BuMines State Mineral Profiler, 1979, 
23 pp. 

31. Sweeney, J. W, , and S. R. Windham. 
Florida: The New Uranium Producer. 
Florida Bureau of Geology Spec. Pub. 22, 
1979, 13 pp. 

32. Texas Instruments Inc. Central 
Florida Phosphate Industry Areawide 
Impact Assessment Program — Volume I: En- 
vironmental Permits and Approvals Re- 
lating to Phosphate Mining and Fertil- 
izer Manufacturing in Florida. September 
1978, 85 pp.; available upon request from 
the Tuscaloosa Research Center, Bureau 
of Mines, P.O. Box L, University, AL 
35486. 



35 



33. U.S. Bureau of Mines. The Florida 
Phosphate Slimes Problem — A Review and a 
Bibliography. BuMines IC 8668, 1975, 41 
pp. 

34. . Phosphate Rock — 1981 (Ad- 
vance Summary). Mineral Industry Survey, 
Apr. 14, 1982, 6 pp. 

35. . Phosphate Rock. Mineral 

Commodity Summaries 1982. 1982, p. 112. 

36. U.S. Comptroller General. Phos- 
phates: A Case Study of a Valuable 
Depleting Mineral In America. Report to 
Congress, EMD-80-21, Nov. 30, 1979, 71 
pp. 

37. U.S. Bureau of Mines and U.S. Geo- 
logical Survey. Principles of a Re- 
source/Reserve Classification For Miner- 
als. U.S. Geol. Survey Circ. 831, 1980, 
5 pp. 

38. Whitney, E. D. Field Testing of 
Seepage Technique for Dewatering the 
Phosphate Slimes. Center for Research in 
Mining and Mineral Resources, Univ. of 
Florida, Gainesville, FL, May 14, 1975, 
7 pp. 

39. Woodward, F. E., and L. Gustafson, 
A Survey of Available Flocculants For Use 
With Phosphatic Clay Slimes. SCF, Inc., 



Oct. 10, 1974, 53 pp.; available upon re- 
quest for the Tuscaloosa Research Center, 
Bureau of Mines, P.O. Box L, University, 
AL 35486. 

40. Zellars-Williams , Inc. Evalua- 
tion of the Phosphate Deposits of Flor- 
ida using the Minerals Availability 
System (Final Report, BuMines Contract 
J0377000). June 1978, 195 pp.; available 
upon request from the Tuscaloosa Research 
Center, Bureau of Mines, P.O. Box L, Uni- 
versity, AL 35486. 

41. . Evaluation of Pre-July 1, 

1975 Disturbed Phosphate Lands, V. 1. 
August 1980, 95 pp.; available upon re- 
quest from the Tuscaloosa Research Cen- 
ter, Bureau of Mines, P.O. Box L, Univer- 
sity, AL 35486. 

42. . Evaluation of Pre-July 1, 

1975 Disturbed Phosphate Lands, V. 2. 
August 1980, 200 pp.; available upon re- 
quest from the Tuscaloosa Research Cen- 
ter, Bureau of Mines, P.O. Box L, Univer- 
sity, AL 35486. 



43. . 

of Reclamation 

Lands in the Phosphate District. 



A Model For Deteinnination 
Methods For Disturbed 

1978, 



135 pp.; available upon request from Tus- 
caloosa Research Center, Bureau of Mines, 
P.O. Box L, University, AL 35486. 



36 



APPENDIX.- 
September 1973 
October 10, 1973 

October 10, 1973 

October 10, 1973-April 9, 1974 

February 1, 1974 
April 11, 1974 

April 11, 1974 
May 13, 1974 

May 13, 1974 

May 15, 1974 

May 22, 1974 

May 28, 1974 
May 30, 1974 



-CHRONOLOGY OF ESTABLISHING A PHOSPHATE OPERATION 
Optioned 7,553 acres in Manatee County. 



August 2, 1974 
October 1, 1974 
October 11, 1974 
October 11, 1974 
October 11, 1974 



Filed a Zoning and Development of Regional Impact 
(DRI) application with Manatee County and State. 

County imposed 6-month moratorium on application 
acceptance while mining ordinance rewritten. 

County writing ordinance; company rewriting 
application. 

Optioned additional 1,360 contiguous acres. 

Manatee Board of County Commissioners passed (5-0) 
new county mining ordinance. 

Company refiled application with Manatee County. 

Company received positive recommendation from 
staff of Tampa Bay Regional Planning Council. 

Recommendation for denial given by Executive 
Committee of Tampa Bay Regional Planning Council. 

Public hearing held by Manatee County Planning 
Commission. 

Manatee County Planning Commission recommended 
approval by 6-to-l vote. 

Manatee County Commissioners held hearing. 

Manatee County Commissioners rejected the company's 
applications for Special Exception for Mining 
(Zoning) and Development of Regional Impact State- 
ment by 5-to-O vote. Reasons for rejection given 
as (1) the use may not be coiiq)atible with reser- 
voirs watershed; (2) a hydrology study is needed 
to show that the consumptive water use is compati- 
ble with surrounding uses. 

Closed on 1,360-acre property as option expired. 

DRI appeal withdrawn. 

Closed on 7,553-acre property as option expired. 

Optioned 1,806 additional contiguous acres. 

New DRI, Environmental Impact Statement, water 
plan, and mining plan filed with Manatee County 
and Tampa Bay Regional Planning Council. 



37 



November 9, 1974 
December 2, 1974 
December 9, 1974 

January 8, 1975 
January 15, 1975 
January 28, 1975 

February 26, 1975 
April 8, 1975 

May 6, 1975 



May 16, 1975 
May 27, 1975 
June 9, 1975 
June 17, 1975 

July 15, 1975 

July 21, 1975 

July 31, 1975 



Manatee County Public Hearing advertised for 
January 8, 1975. 

Application for Special Exception for Mining 
(Zoning) refiled. 

Tampa Bay Regional Planning Council Executive 
Committee votes unanimously a recommendation for 
approval of the DRI application. 

Public hearing held by Manatee County for review 
of DRI and Special Exception. 

Recommendation for approval voted unanimously by 
the Manatee County Planning Commission. 

Approval by Manatee County Board of County Com- 
missioners of DRI and Special Exception for 
Mining voted unanimously (5-0). 

DRI appeal filed by Sarasota County. 

State of Florida Department of Environmental Regu- 
lation Sanitary Waste, Industrial Waste, and Air 
Pollution permits filed by the coiiq)any. 

Manasota Basin Board recommended approval of the 
conq)any's water use based on an extensive hydrol- 
ogy study monitored by State and U.S. Geological 
Survey personnel. 

Federal Environmental Protection Agency permit 
application filed. 

Corps of Engineers permit application filed. All 
permit applications now filed. 

Turnkey contract signed with Jacobs Engineering 
for benef iciation plant construction. 

Governor and Cabinet upheld coiiq)any and denied 
Sarasota County's appeal before the Florida Land 
and Water Adjudicatory Commission. 

Sarasota County filed Writ of Certiorari with 
First District Court of Appeals seeking review of 
order issued June 17, 1975. 

Sarasota County appealed to First District Court 
of Appeals to reverse rule of Florida Land and 
Water Adjudicatory Commission. 

State of Florida Air Pollution Construction Permit 
approved. 



38 

July 31, 1975 

August 11, 1975 
October 13, 1975 



May 24-26, 1976 



June 22, 1976 



July 1, 1976 



July 8, 1976 



August 13, 1976 



August 1976 



September 9, 1976 



October 9, 1976 



October 15, 1976 



Petition filed by Sarasota County with Department 
of Environmental Regulation to intervene regard- 
ing permit applications by the company. 

Closing on 1,806-acre property as options expired. 

First District Court of Appeals denied company 
request that Sarasota post bond to indemnify 
company for losses incurred by harrassment and 
delays. Court did agree to pronq)tly hear Sara- 
sota's July 21, 1975, appeal. 

Public hearing before State of Florida Hearing 
Officer relative to Florida Department of En- 
vironmencal Regulation Industrial Wastewater 
Discharge Construction Permit. Sarasota County 
and Longboat Key appeared as adversary parties. 

U.S. EPA public hearing on company's National pol- 
lutant Discharge Elimination System (NPDES) draft 
permit, 

Florida Hearing Officer's recommendation made rec- 
commending denial of State of Florida's intent 
to grant company's Industrial Wastewater Dis- 
charge Construction Permit based on a new inter- 
pretation of rules, not previously enforced. 

Prehearing conference date for Sarasota's appeal 
of U,S, EPA's company NPDES Existing Source 
determination. 

Secretary of Department of Environmental Regula- 
tion rejected Hearing Officer's recommendation 
and issues final order, with stipulations, to 
company (Florida Industrial Wastewater Permit), 

Sarasota County filed an appeal to decision on 
Florida Industrial Wastewater Periait. 

Department of Army Corps of Engineers public hear- 
ing on company's application to construct two 
secondary containment structures, Sarasota 
County requested this hearing and filed objec- 
tions to the construction of these structures. 

Record closed on comments to Corps of Engineers 
re company's secondary containment structures. 
Decision expected in November 1976, 

Appeal to State Department of Environmental Regu- 
lation Board re company's Wastewater Permit was 
originally expected to be heard October 15, 1976, 
but was rescheduled to December 1, 1976, as a 
result of a delay requested by Sarasota County. 



39 



November 6, 1976 

November 9, 1976 
November 12, 1976 
November 29, 1976 
December 1, 1976 

December 27, 1976 

December 1976 

January 26, 1977 



February 8, 1977 
February 10, 1977 

February 19, 1977 



February 28, 1977 

March 18, 1977 

March 18, 1977 
April 15, 1977 



Department of Environmental Regulation (DER) Dredge 
and Fill Public Notice published in Bradenton 
Herald. 

DER staff member recommended Dredge and Fill 
application denial. 

Sarasota County filed petition to intervene in the 
proceedings re DER Dredge and Fill application. 

DER staff report issued recommending denial of 
Dredge and Fill application, 

DER Board voted 3-2 to reverse Secretary Lander's 
final order, thereby denying company's Industrial 
Wastewater Permit. 

Company granted a rehearing before the DER Board 
January 26, 1977, re the Industrial Wastewater 
Permit denial. 

Company filed for and was granted an Administra- 
tive Hearing relative to the Dredge and Fill 
recommended denial. 

Company had rehearing before DER Board re Indus- 
trial Wastewater Permit. Board voted unanimously 
to reverse itself and approve company's Indus- 
trial Wastewater Permit. 

Florida DER issued certification for company's 
Federal NPDES Permit. 

Final order issued by Environmental Regulation 
Commission adopting Florida DER final order 
granting company's Industrial Wastewater Permit. 

Prehearing conference in Tallahassee re company's 
appeal of Florida DER staff's recommended denial 
of Dredge and Fill application, Sarasota County 
joined action in opposition to company. Manatee 
County proposed joining in support of company. 
Hearing scheduled for April 21-22, 1977. 

State of Florida DER Industrial Wastewater Dis- 
charge Construction Permit issued. 

Manatee County Building (Construction) Permit 
issued. 

Federal EPA-NPDES Notice of Issuance signed. 

Manatee County Commissioners agreed to modify 
company DRI for eliminating the requirement to 
complete secondary dams prior to operation. 



40 



April 21, 1977 



May 9, 1977 



May 10, 1977 
July 13, 1977 

August 3, 1977 



September 21-23, 1977 

October 1977 
November 2, 1977 

November 28-30, 1977 

December 6, 1977 
December 7, 1977 
December 16, 1977 
January 12, 1978 
January 21, 1978 



Dredge and Fill Permit Administrative hearing post- 
poned pending hearing on Manatee DRI modification 
(dams). 

City of Sarasota attempted to appeal Manatee DRI 
modification through Tampa Bay Regional Planning 
Council (TBRPC). Appeal defeated with only Sara- 
sota voting for it. TBRPC approved modification. 

Sarasota appealed Manatee action (dams) through 
Southwest Florida Regional Planning Council, 

DRI modification prehearing conference. Hearing 
officer refused company petition for dismissal. 
Hearing tentatively set for late September, 

1, Southwest Florida Water Management District 
(SWFWMD) Board voted not to declare Manatee 
County a water shortage area, 

2. SWFWMD Board approved rules for Sarasota Basin 
area. 

3, SWFWMD Board passed a resolution regarding de- 
velopment of stricter rules in stressed areas 
(Board Identified most of Manatee County as a 
stressed area). 

4. Conq>any Phosphate Corporation's Water Consump- 
tive Use Applications were accepted (fee paid). 

DRI modification hearing held in St. Petersburg 
before State Hearing Officer. 

Prehearing conference re Water Use Permit. 

Company Water Use Permit unanimously approved by 
Water Management District Board at public hearing. 

Sarasota's appeal of company's EPA Permits held 
before Federal Hearing Officer in Sarasota Court 
House. 

Sarasota appealed Water Use Permit to Governor ana 
Cabinet. 

Completed application for Manatee County Operating 
Permit filed. 

State Hearing Officer found in company's favor re 
DRI hearing held Sept. 21-23. 

Sarasota County appealed decision of Dec. 16, 1977 
re DRI to Governor and Cabinet. 

Water Management District asked Governor and Cabi- 
net to dismiss Sarasota appeal of company's Water 
Permit. 



41 



January 1978 

February 7, 1978 
February 14, 1978 

February 14, 21, 1978 

February 28, 1978 
March 13, 1978 



March 17, 1978 



March 23, 1978 



April 3, 1978 



April 6, 1978 



May 2, 1978 



May 8, 1978 
May 12, 1978 

July 18, 1978 



Regional Planning Council and Manatee County joined 
coiiq)any in asking Governor and Cabinet to dismiss 
Sarasota appeal of company's DRI modification. 

Governor and Cabinet remanded DRI appeal to hearing 
officer for reconsideration based on technicality. 

Manatee County Operating Permit hearing set. This 
was last permit needed prior to initiation of 
mining operations. 

Manatee County Operating Permit approval deferred 
for further discussions. 

Manatee County Operating Permit approved, 

DRI hearing (remand) continued in Tallahassee 
attended by company, Manatee County, Tampa Bay 
Regional Planning Council, Sarasota County, and 
South Florida Regional Planning Council. 

DRI hearing officer again ruled in company's favor 
and forwarded his decision to Governor and 
Cabinet for April 6, Tallahassee meeting, 

Sarasota County's appeal of company's SWFWMD Water 
Use Permit heard by the Governor and Cabinet in 
Tallahassee, The Cabinet asked the lawyers to 
brief a legal issue re Sarasota's appeal rights, 

EPA Administrative Law Judge Yost issued his rec- 
ommended decision to the EPA Regional Administra- 
tor for review, prior to release (Re EPA existing 
source and wastewater discharge permit). 

The Governor and Cabinet reheard the DRI appeal 
and ruled in Company's favor, dismissing the 
Sarasota appeal. 

Regional Administrator, EPA Region IV John C. White 
redetermined that the Company mine and beneficia- 
tion plant in Manatee County is an "existing 
source" and hence found in Company's favor. 

Sarasota County filed with Court of Appeals peti- 
tion re Governor's DRI ruling. 

Sarasota County petitioned EPA Administrator 
Douglas Cos tie for review of Regional Administra- 
tor's decision. 

Governor and Cabinet allowed Sarasota County to be- 
come a party to Water Use Permit proceedings and 
remanded the permit to SWFWMD for reconsideration. 



42 



July 18, 1978 



August 2, 1978 



December 15, 1978 

February 7, 1979 
February 22, 1979 
February 22, 1979 
May 15, 1979 

December 24, 1980 
May 7, 1981 
May 1981 
May 1981 

June- July 1981 
August-September 1981 
November 1981 
1981-82 

Fall 1981-Winter 1982 
Fall 1981-Winter 1982 
Fall 1981 



Manatee County Commission deferred acceptance of 
method of company financial responsibility until 
90 days prior to mining. 

SWFWMD reconsidered company Water Use Permit and 
again approved company's application, extending 
the expiration data from Nov. 1, 1983 to Aug. 1, 
1984. 

State of Florida Department of Natural Resources 
approves Company's reclamation and restoration 
programs. 

Florida First District Court of Appeals found in 
company's favor re Sarasota County DRI appeal. 

First District Court of Appeals ruling on DRI 
became final; further appeal period lapses. 

EPA Administrator Douglas Cos tie ruled in company's 
favor, finding company to be an "existing source." 

Florida Department of Environmental Regulation 
extended Air, Water, and Domestic Waste Permits 
to Feb. 28, 1983. 

Building permits withheld. 

Maintenance building permit granted. 

Building permit approved. 

Financial responsibility insurance policy for $13 
million filed with county. 

Financial responsibility hearings approved. 

Reclamation plan submitted and approved. 

Plant startup. 

Various subpermits for road crossings, pipelines, 
etc. 

Applications for wetland activities pending. Areas 
included farm ditches, grove drainages, and 
perched water areas. 

Challenges to various previously approved permits 
were made by local and State agencies. New hear- 
ings scheduled. 

New mining ordinance and reservoir protection dis- 
trict and special treatment district ordinances 
passed by county to extend mining regulation. 



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